The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Critical aspects for assessment and evidence include:

the breaking and making of a flanged joint in accordance with the organisation’s flange management procedure

recognising own skill limits and when to refer to another person.

Context of and specific resources for assessment

Assessment of this competency will occur over a range of situations which will include typical disruptions to normal, smooth operation. This will require access to a plant over a period of time, or a suitable method of gathering evidence of operating ability. Where safety, lack of opportunity or significant cost is an issue, an industry-based simulation may be employed to assist the process.

Guidance information for assessment

Assessment processes and techniques must be appropriate to the language, competency and safety requirements of the site and consistent with workplace systems or procedures.

Required skills

Required skills include:

using a limited range of hand tools

recognising conditions which will lead to a poor joint

implementing enterprise procedures within time constraints and in a manner relevant to the correct use of the equipment

conveying information relevant to the operation clearly and effectively

maintaining appropriate levels of quality assurance

reading and numeracy to interpret/complete workplace documents and technical information

applying mathematics required for the use of calibration charts

Required knowledge

Required knowledge of flange jointing principles and typical problems to a level needed to break and make flanged joints using hand tools, includes:

all flange and gasket types as applicable

principles of how flanged joints seal

tool types and applications

organisation’s flange management procedure

duty of care obligations

hierarchy of control

communication protocols, e.g. radio, phone, computer, paper and permissions/ authorities

typical issues causing problems and the resolution of those problems

routine problems, faults and their symptoms ,and the corrective action to be taken

process materials and conditions at the location of the flange

function and troubleshooting for addressing leaks

using flange tags/completeness tags

relevant environmental requirements

relevant parts of ASME PCC-1-2010 Guidelines for Pressure Boundary Bolted Flange Joint Assembly

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Context

This competency includes breaking and making flange joints using hand tools. It does not include the use of:

pneumatic torqueing tools

hydraulic torqueing tools

powered torqueing tools

Work requirements

Work requirements may include but are not limited to:

flange and gasket specifications

stud and nut specification

process line and process materials

parts and equipment required

local detectors requiring isolation

required skill level

conflicting work

Work requirements may come from briefings, handovers, and work orders and may include:

compliance documentation

product specifications

nature and scope of tasks

achievement targets

operational conditions

lighting conditions

plant or equipment defects

hazards and potential hazards

coordination requirements or issues

Job site

Inspecting job site may include but is not limited to identifying:

location

authorisations required

access and egress needs

hazards

recent work undertaken on joint

flange type (matches specification)

Control hazards

Control hazards may include but is not limited to:

selection and use of appropriate personal protective equipment

obtaining appropriate authorisations

checking required isolations

controlling other work in area

Implement hazard controls

Implementing hazard controls may include but is not limited to:

controlling access to area

using gas tester

verifying and confirming isolation

safe flange breaking procedure (line of fire)

Manage open pipe

Manage open pipe includes:

all those actions required once the flange is broken to ensure the pipe and its contents are not contaminated or damaged

Inspect components

Inspecting flange components may include but is not limited to:

checking for asbestos in gaskets

looking for signs of damage, defects or deterioration in all components

cleanliness and correct surface roughness of mating surfaces

alignment

Refer to appendices of ASME PCC-1-2010 Guidelines for Pressure Boundary Bolted Flange Joint Assembly for technical details

Components

Components may include but are not limited to:

studs

nuts

washers

gaskets

Check studs and nuts

Checking studs and nuts may include but is not limited to checking:

integrity of studs and nuts

fit of nut to stud

need for new studs and nuts

conformance to specification

Initial assembly of joint

Initial assembly of joint may include but is not limited to:

aligning joint

inserting studs

assembling nuts to studs

inserting and aligning gasket

Blinds

Blinds may include but are not limited to:

blinds

blanks

spectacle/goggle blinds

Refer

Refer means to refer the issue to the person with the required skills, knowledge and/or authority to deal with the matter

Procedures

Procedures may be written, verbal, computer-based or in some other form. They may include but are not limited to:

flange management procedures

all work instructions

standard operating procedures

temporary instructions

any similar instructions provided for the smooth running of the plant

good operating practice as may be defined by industry codes of practice

Procedures would be expected to comply with any relevant government regulations.

Checklists and records

Checklists and records may include:

paper or electronic based and verbal/radio reports

reporting items found which require action

Appropriate action

Appropriate action includes but is not limited to:

determining problems needing action

accessing and applying relevant technical and plant data

applying appropriate problem solving techniques to determine possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility/ability to resolve to designated person

Typical problems

Typical problems may include but are not limited to:

seal/gasket leaks

pressure loss/low flow

blockages/build-up/fouling

erosion/wear

ancillary equipment problems

studs incorrectly tensioned

worn threads

misalignments

cold pull

isolation failure

leak test failure

Remedial actions

Remedial actions may include but are not limited to:

replacing existing components with new components

carrying out minor maintenance within operator's skill level

identifying and reporting problems outside operator's competence

identifying and controlling hazards related to flange joints

Health, safety and environment (HSE)

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.